Support systems for a reclining or a sitting body

ABSTRACT

A support system including a middle layer having two opposite convoluted sides positioned on the outer surface of the support system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of and priority to U.S. Provisional application 62/198,401, filed Jul. 29, 2015.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed towards a support system for a reclining or sitting body. More particularly, the invention relates to a mattress or a cushion.

BACKGROUND

Support systems for a sitting or reclining body, such as a mattress, seat cushion, or pillow, for example, with varying body support from soft to firm are known. Polyurethane foams may be cut from a single block of foam to form a shaped top surface and a bottom planar surface. The shaped top surface may be formed by cutting and removing portions of foam from the top surface. Convoluted cutting is one known method to achieve peaks and valleys on one surface of a foam block while discarding the portion of foam that is removed.

SUMMARY OF THE INVENTION

In one aspect, the invention is directed towards a support system for a reclining or sitting body, such as, but not limited, to, a mattress or a cushion. The support system, e.g., a mattress according to an exemplary embodiment, includes a middle layer core (which in one embodiment is the only layer) having a first polyhedral foam layer and a second polyhedral foam layer each having a first indentation load deflection (ILD). Each of the first and second polyhedral foam layers include a longitudinal planar first surface and a longitudinal convoluted second surface that is opposite and parallel to the first planar surface. The planar surface of the first layer is joined to the planar surface of the second layer. In this embodiment, the upper and lower surfaces of the support system are convoluted.

In another embodiment, the ILD of the first and second polyhedral foam layers may differ.

In still other embodiments of this aspect of the invention, the support system further includes a third layer that may or may not have an ILD that is different, such as greater or less than the IUD of the first and the second polyhedral foam layers. The third layer abuts or is joined to the convoluted surface of the first and second polyhedral foam layers, Optionally, the third layer is a sleeve which covers all surfaces of and encloses the first and second polyhedral foam layers, For example, the sleeve may be a quilted fabric.

In other embodiments of this aspect of the invention, the convoluted surface of the first and the second polyhedral foam layers of the core of the mattress or cushion comprises a plurality of zones comprising peaks and valleys.

In one embodiment, the zones of peaks and valleys of the convoluted surface of the first polyhedral foam layer are identical to the peaks and valleys of the convoluted surface of the second polyhedral foam layer. The peaks and the valleys of the first polyhedral foam layer and the second polyhedral foam layer are positioned on opposite sides of the core.

In a particular embodiment, the first polyhedral foam layer and the second polyhedral foam layer are removed, i.e., cut from the same piece of foam material.

In another aspect, the invention is directed towards a method of making a support system, e.g., a mattress or a cushion. In one embodiment, the method includes transversely sectioning such as by cutting with a blade or cutting by application of heat, a block of foam longitudinally through the foam piece to form two pieces of foam having substantially the same length. The foam pieces may be identical in thickness or different in thickness. The manufacturing steps include providing a first polyhedral foam layer and a second polyhedral foam layer by cutting a block of foam as described above, each comprising a first ILD. The foam block is cut to form two pieces, each with a convoluted cut surface. Accordingly, each of the first polyhedral foam and second polyhedral foam layers include a longitudinal planar first surface and a longitudinal convoluted second surface that is opposite and parallel to the first planar surface. The first planar surface of the first polyhedral foam layer is joined to the first planar surface of the second polyhedral foam layer.

In one embodiment of this aspect of the invention, a third foam layer, as described above, is provided and covers the longitudinal convoluted surface of the first polyhedral foam layer and the second polyhedral foam layer thereby forming the support system, for example, a mattress. Optionally, the third layer comprises a quilted fabric.

The invention described below has advantages over the prior art for at least the following reasons:

(i) by gluing two convoluted foam pieces back-to-back (planar surface-to-planar surface), a manufacturer is able to produce a foam mattress (or cushion) core at a specified height using less foam materials than prior art methods of gluing a convoluted foam layer on top of a planar foam layer and for this reason, the foam mattress or cushion core described herein is less expensive to manufacture;

(ii) after joining two convoluted foam pieces back-to-back, such as by use of an adhesive, the foam mattress (or cushion) is reversible, both sides of the mattress having a foam material of the same indentation load deflection (ILD);

(iii) the foam mattress core (or cushion) according to the invention below is lighter than known constructions due to the use of less foam materials which makes the mattress easier for a consumer to carry;

(iv) the process described below of producing a convoluted core in a mattress (or cushion) is less labor and capital intensive than prior art convoluted foam core mattresses. In the prior art, a foam core with convoluted layer mattress, is manufactured by fabricating two foam layers, one of the two layers is convoluted, and then the convoluted piece is glued to a planar foam core piece. With the method of the invention described below, one piece of foam is fabricated and then convoluted to form two pieces of foam having a convoluted side on each of the two pieces of foam. Accordingly, the labor and machine time is considerably less than prior art methods and mattresses;

(v) the quality of the mattress (or cushion) is improved compared to a mattress such as a two piece foam mattress in which the planar surface of a first foam piece having an opposite convoluted surface is applied to the convoluted surface of a second foam piece also having an opposite planar surface, resulting in a finished mattress with a convoluted surface on one side of the two piece foam mattress and a planar surface on the opposite side of the two piece foam mattress; and,

(vi) the construction of the mattress or cushion described herein with convoluted foam on the top and bottom surfaces of the mattress core provides a softer foam core which provides more pressure relief for the consumer,

In summation, the present invention is advantageous over prior art support systems such as mattresses or cushions and methods of making, because it (a) uses less materials, (b) uses less labor, (o) uses less equipment time, (d) is lighter, (e) is reversible with identical ILI) on both sides and (f) adds comfort not found in prior art foam mattresses.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective side view of a support system for a reclining or sitting person according to an exemplary embodiment of the invention.

FIG. 2A illustrates a perspective side view of an exemplary embodiment of a polyhedral foam partially transversely cut to form an upper first and a lower second layer of the middle layer of the support system illustrated in FIG. 1. FIG. 2B illustrates a side perspective view of an exemplary embodiment of a polyhedral foam completely cut transversely to form two layers: an upper first and a lower second layer of a support system having an exemplary three zones each with peaks and valleys.

FIG. 3 illustrates a side view of an exemplary embodiment of a support system according to the invention exclusive of the third layer of the support system illustrated in FIG. 1 formed from the foam layer illustrated in FIG. 2A.

FIG. 4 illustrates a side view of the support system with top and bottom portions of a third layer abutting or joined to the peaks of the upper first and lower second layers of the middle layer illustrated in FIG. 3 according to an exemplary embodiment of the invention.

DESCRIPTION OF THE INVENTION

The following description includes the best contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

Various inventive features are described below in which each may be used independently of one another or in combination with other features.

In general the invention is directed to a support system for a reclining or a sitting mammalian body, such as a human body.

Broadly, embodiments of the present invention generally provide a support system for a reclining or sitting body. The support system may be, for example, a mattress, or a cushion, for example a seat cushion. In one embodiment the support system of the invention. provides one or more layers of a mattress, in another embodiment the support system provides a mattress, in yet another embodiment the support system provides a seat cushion or a seat back for a chair, for example, an auto or truck seat or an airplane seat.

Aspects of the present invention generally provide a polyhedral such as a hexahedron support system typically greater in length than in width. The support system comprises a core or a middle layer (which is the only layer in one embodiment) comprising a first and a second layer of a synthetic foam material joined together. The first and second layers of the middle layer of the support system include at least one zone, typically a plurality of zones, one or more zones comprising one or more ridges and valleys, i.e., one or more convolutions. The hexahedron optionally includes a third layer including an upper outer layer and a lower outer layer, each comprising a synthetic foam, quilted material or other fabric material. The upper and lower layers may form a third layer sleeve, or a third layer envelope completely enclosing; i.e., covering all surface of the middle layer core described above. The ILD of the middle layer is typically greater than the ILD of the upper outer and lower outer layers. The zones or convolutions of the first and second layers of the middle layer abut the upper outer and lower outer layers, respectively, thereby forming the synthetic foam hexahedron support system.

As used herein, a lower layer shall mean a layer positioned between the earth's center of gravity and an upper layer.

As used herein, a top surface of an object shall mean a surface further away from the earth's center of gravity than the bottom surface of said object.

As used herein, the bottom surface of an object is the underside of the object.

As used herein, indentation load deflection (ILD) shall mean a measurable amount of deflection in response to an applied force.

Referring now to FIG. 1, a perspective side view of a hexahedron support system 100 according to an exemplary embodiment of the present invention is generally illustrated. In the illustrated embodiment, a third layer consisting of an upper outer layer 94 and a lower outer layer 84, further described below, is illustrated. The third layer may be a sleeve or envelope completely enclosing the middle layer 10. The support system 100 according to the invention may be exclusive of the upper outer 94 and lower outer 84 layers and include only a core middle layer 10.

Support system 100 has a first end 70, a second end 60, a first side 30, a second side 20, a top surface 50 and a bottom surface 40. Typically the first end 70 and the second end 60 are shorter in length than the first side 30 and the second side 20. The shape of the support system 100 is typically a hexahedron and may include the first upper outer layer 94, the second lower outer layer 84, and the third middle layer 10. The thickness or depth of the upper outer layer 94 may be the same as or different than the thickness or depth of the lower outer layer 84. The thickness of middle layer 10 is typically greater than the thickness of the upper outer layer 94 or the lower outer layer 84 as described in greater detail as follows.

With continued reference to FIG. 1, the middle layer 10 has two foam layers: an upper middle layer 90 and a lower middle layer 80. The upper middle layer 90 and the lower middle layer 80 are joined together along their planar surfaces described below in greater detail. In one embodiment of the invention, the upper middle layer 90 and the lower middle layer 80 have identical dimensions.

Synthetic foam materials that may be used for the upper, middle and lower layers include, for example, polyurethane foam, polyurethane gel foam, viscoelastic polyurethane foam, and combinations thereof.

The middle layer 10 is formed by cutting a layer of synthetic foam 11 transversely along its long axis through the center 12 of the foam layer from one end of the layer of foam 11 to the other end as illustrated in FIG. 2A. In one embodiment, the layer of synthetic foam 11 is transversally cut through the center thereby forming two identical layers, i.e., upper middle layer 90 and lower middle layer 80.

In one embodiment of the support system 10, with continued reference to FIG. 2A, the cut surface of each middle layer 90 and middle layer 80 is convoluted including one or more peaks (ridges) 96 and 86, and one or more valleys 96′and 86′, respectively, in a uniform arrangement, a random arrangement, or arranged in one or more zones.

In one embodiment according to the invention, each of the upper middle layer 90 and the lower middle layer 80 of the middle layer 10 include a plurality of zones 40, extending from the one end to the opposite end of the cut surface of upper middle 90 and lower middle 80 layers. For example, as illustrated in FIG. 2B, the cut surface may have three zones 40 a, 40 b, 40 c having peaks and valleys, extending from one end to the opposite end of the foam layer 11. The convolutions or zones extend transversely across the width of each layer as shown in FIG. 2A. Typically, although not exclusively, the number and position of the peaks and valleys in the upper middle layer 90 are the same as the number and position of the peaks and valleys in the lower middle layer 80. In other words, the peaks, i.e., ridges in one layer correlate with the valleys in the other layer. The number of peaks/valleys or zones illustrated in FIGS. 2 and 2AB are merely exemplary and do not limit the possible number of peaks/valleys or zones, combinations or the distribution of peaks/valleys or zones according to the invention.

Referring now to FIG. 3, middle layer 10 of the support system 100 is illustrated. In the illustrated embodiment, middle layer 10 comprises the polyhedral foam layer 80 identical to the polyhedral foam layer 90 cut from polyhedral foam layer 11 as described above with respect to FIGS. 2A and 2B. The planar surface 98 of layer 90 is joined to planar surface 88 of layer 80 to form middle layer 10. Planar surfaces 98 and 88 are joined by an adhesive, thermal or chemical bonding. Following joining layer 80 and layer 90 along their planar surfaces, the outer surfaces 50 and 52 are opposite, convoluted surfaces as shown in FIG. 3.

According to one embodiment of the support system 100 illustrated in FIG. 3, after layer 90 is joined to layer 80, the convoluted surface and peaks 96 of layer 90 and the convoluted surface and peaks 86 of layer 80 are located on the top 50 and bottom 52 exterior surfaces, respectively, of middle layer 10.

With reference now to FIG. 4, in one embodiment of the support system 100, a first upper layer 92 is applied to the peaks 96 of the upper middle layer 90 of middle layer 10 and a second lower layer 82 is applied to the peaks 86 under the second lower layer 80 of middle layer 10. The length and width of upper layer 92 and the length and width of lower layer 82 is identical to the length and width of middle layer 10.

Once assembled in the support system embodiment illustrated in FIG. 4, in one embodiment the entire assembly is encased in a fabric material 94, for example, as a sleeve or envelope, such as a quilted material that includes layers 82 and 92 to provide additional comfort or support. The fabric material may be secured to the mattress by conventional means, e.g., a. connector such as a flange or threading. The layers 82 and 92 may lie directly, Le., in contact with middle layer 10.

According to exemplary embodiments of the invention, support system 100 may have varying lengths and widths corresponding to standard dimensions for American and European support systems for a reclining or sitting person.

The advantages of the support system, e.g., a mattress or cushion, include but are not limited to (i) a less expensive, less labor-intensive, higher quality, and easier to manufacture support system because one block of foam is used to generate two foam pieces each with a convoluted surface, (ii) a lighter support system because less foam is required, (iii) a reversible support system having a convoluted surface on opposite sides of the support system, each of the two foam pieces having an identical ILD; and (iv) a more comfortable, with added support system because a convoluted surface is positioned both adjacent to the top and the bottom of the support system.

It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

I claim:
 1. A mattress, comprising: a core comprising a first polyhedral foam layer and a second polyhedral foam layer, each of the first and second polyhedral foam layers comprising a first indentation load deflection, each of the first and second polyhedral foam layers further comprising a longitudinal planar first surface and a longitudinal convoluted second surface opposite and parallel to said first planar surface, said planar surface of said first polyhedral foam layer joined to said planar surface of said second polyhedral foam layer.
 2. The mattress of claim 1 wherein the convoluted surface of the first and the second polyhedral foam layers of the core comprise a plurality of zones comprising peaks and valleys.
 3. The mattress of claim 2 wherein the zones of peaks and valleys of the convoluted surface of the first polyhedral foam layer is identical to the peaks and valleys of the convoluted surface of the second polyhedral foam layer.
 4. The mattress of claim 2 wherein the peaks and the valleys of the first polyhedral foam layer and the second polyhedral foam layer are positioned on opposite sides of the core.
 5. The mattress of claim 1 further comprising a third layer comprising an indentation load deflection that is different than the first indentation load deflection.
 6. The mattress of claim 5 wherein the third layer encloses the core.
 7. The mattress of claim 5 wherein the third layer comprises an indentation load deflection that exceeds the indentation load deflection of the first indentation load deflection.
 8. The mattress of claim 1 wherein the first polyhedral foam layer and the second polyhedral foam layer are removed from the same piece of foam material.
 9. A method of making a mattress, comprising: transversely sectioning a piece of foam material to form a first polyhedral foam piece and a second polyhedral foam piece, each of the first and second polyhedral foam pieces providing a first and a second polyhedral foam layer comprising a first indentation load deflection, a longitudinal planar first surface, and a longitudinal convoluted second surface opposite to said. first planar surface; and, joining said first planar surface of said first polyhedral foam layer to the first planar surface of said second polyhedral foam layer.
 10. The method of claim 9 further comprising applying a third layer comprising an ILD different than the first ILD to the longitudinal convoluted surface of said first polyhedral foam layer and to said longitudinal convoluted surface of the second polyhedral foam layer thereby forming said mattress.
 11. The method of claim 10 wherein said third layer comprises a quilted fabric. 